Processes and Systems for Co-Processing a Hydrocarbon Feed and a Heavy Feed Containing a Plastic Material

Abstract

Processes and systems for hydrocarbon pyrolysis. In some embodiments, a hydrocarbon can be heated within a convection section of a steam cracking furnace and combined with an aqueous fluid to produce a heated mixture. A heavy feed that includes a plastic material can be introduced into a vessel and a portion of the plastic material can be cracked therein. Liquid and vapor effluents exiting the vessel can be obtained. At least a portion of the liquid effluent can be heated to produce a heated fluid stream that can be recycled to the vessel. The vapor effluent can be combined with the heated mixture to produce a combined mixture that can be heated within the convection section to produce a heated combined mixture. At least a portion of the heated combined mixture can be cracked within a radiant section of the steam cracking furnace to produce a steam cracker effluent.

What is claimed is: 
     
         1 . A process for converting hydrocarbons by pyrolysis, comprising:
 heating a hydrocarbon feed within a convection section of a steam cracking furnace and combining the hydrocarbon feed with an aqueous fluid to produce a heated mixture comprising hydrocarbons and steam, wherein the heating is carried out before, during, and/or after the hydrocarbon feed is combined with the aqueous fluid;   introducing a heavy feed comprising a plastic material into a vessel;   cracking a portion of the plastic material in the vessel under plastic pyrolysis conditions;   obtaining a liquid phase effluent and a vapor phase effluent exiting the vessel;   heating at least a portion of the liquid phase effluent to produce a heated fluid stream;   recycling at least a portion of the heated fluid stream to the vessel;   combining the vapor phase effluent with the heated mixture to produce a combined mixture;   heating the combined mixture within the convection section of the steam cracking furnace to produce a heated combined mixture; and   steam cracking at least a portion of the heated combined mixture within a radiant section of the steam cracking furnace to produce a steam cracker effluent comprising olefins.   
     
     
         2 . The process of  claim 1 , wherein the liquid phase effluent is heated in an internal heat exchanger disposed within the convection section of the steam cracking furnace. 
     
     
         3 . The process of  claim 1 , wherein the liquid phase effluent is heated within an external heat exchanger located outside of the steam cracking furnace. 
     
     
         4 . The process of  claim 3 , wherein the liquid phase effluent is heated within the external heat exchanger by transferring heat from a heated hydrocarbon, a heated aqueous fluid, or a combination thereof, or by transferring heat from one or more electrical heating elements, or a combination thereof, and wherein, if present, the heated hydrocarbon comprises the stream cracker effluent, a cooled steam cracker effluent, a refinery hydrocarbon-containing stream, or a combination thereof. 
     
     
         5 . The process of  claim 1 , further comprising removing a portion of the liquid phase effluent from the process. 
     
     
         6 . The process of  claim 1 , wherein the heavy feed further comprises a carrier liquid mixed with the plastic material. 
     
     
         7 . The process of  claim 1 , further comprising mixing a carrier liquid with at least a portion of the liquid phase effluent to produce a combined liquid phase mixture, wherein the combined liquid phase mixture is heated to produce the heated fluid stream. 
     
     
         8 . The process of  claim 1 , wherein the liquid phase effluent comprises a char, and the process further comprises:
 introducing at least a portion of the liquid phase effluent into a separation vessel; and   separating at least a portion of the char from the at least a portion of the liquid phase effluent to produce a char-lean liquid phase effluent, wherein at least a portion of the char-lean liquid phase effluent is heated to produce the heated fluid stream.   
     
     
         9 . The process of  claim 8 , wherein the heavy feed further comprises a carrier liquid mixed with the plastic material. 
     
     
         10 . The process of  claim 8 , further comprising mixing a carrier liquid with at least a portion of the char-lean liquid phase effluent to produce a combined liquid phase mixture, wherein the combined liquid phase mixture is heated to produce the heated fluid stream. 
     
     
         11 . The process of  claim 6 , wherein the carrier liquid comprises a heat-soaked and/or hydrotreated hydrocarbon stream having an initial boiling point of at least 300° C. 
     
     
         12 . The process of  claim 1 , wherein the plastic material comprises a contaminant-containing polymer and/or the heavy feed further comprises a compound comprising a contaminant, and wherein the vapor phase effluent further comprises one or more contaminant-containing compounds, the process further comprising:
 contacting the vapor phase effluent with a guard bed to remove at least a portion of the one or more contaminant-containing compounds to produce a contaminant-lean vapor phase stream, wherein the contaminant-lean vapor phase stream is combined with the heated mixture to produce the combined mixture.   
     
     
         13 . The process of  claim 12 , wherein the plastic material comprises the contaminant-containing polymer, and wherein the contaminant-containing polymer comprises polyvinyl chloride, polyvinylidene chloride, chlorinated polyvinyl chloride, or a mixture thereof. 
     
     
         14 . The process of  claim 1 , wherein the plastic pyrolysis conditions in the vessel comprises a temperature in a range from 300° C. to 550° C. 
     
     
         15 . The process of  claim 1 , wherein the plastic material comprises a nitrogen-containing polymer, a chlorine-containing polymer, an oxygen-containing polymer, a polyethylene polymer, a polypropylene polymer, a polystyrene polymer, a polyamide polymer, polyethylene terephthalate, ethylene vinyl acetate, a butadiene polymer, an isoprene polymer, an isobutylene polymer, or a mixture thereof. 
     
     
         16 . The process of  claim 1 , wherein the hydrocarbon feed comprises crude oil or a fraction thereof. 
     
     
         17 . A process for converting hydrocarbons by pyrolysis, comprising:
 heating a hydrocarbon feed within a convection section of a steam cracking furnace and combining the hydrocarbon feed with an aqueous fluid to produce a heated mixture comprising hydrocarbons and steam, wherein the heating is carried out before, during, and/or after the hydrocarbon feed is combined with the aqueous fluid, and wherein the heated mixture is a two-phase gas/liquid mixture;   introducing the heated mixture and a heavy feed comprising a plastic material into a vessel;   cracking a portion of the plastic material within the vessel under plastic pyrolysis conditions;   obtaining a liquid phase effluent and a vapor phase effluent exiting the vessel;   heating at least a portion of the liquid phase effluent to produce a heated fluid stream;   recycling at least a portion of the heated fluid stream to the vessel;   heating the vapor phase effluent within the convection section of the steam cracking furnace to produce a heated vapor phase effluent; and   steam cracking the heated vapor phase effluent within a radiant section of the steam cracking furnace to produce a steam cracker effluent comprising olefins.   
     
     
         18 . The process of  claim 17 , wherein the liquid phase effluent is heated in an internal heat exchanger disposed within the convection section of the steam cracking furnace. 
     
     
         19 . The process of  claim 17 , wherein the liquid phase effluent is heated within an external heat exchanger outside of the steam cracking furnace. 
     
     
         20 . The process of  claim 19 , wherein the liquid phase effluent is heated within the external heat exchanger by transferring heat from a heated hydrocarbon, a heated aqueous fluid, or a combination thereof, or by transferring heat from one or more electrical heating elements, or a combination thereof, and wherein, if present, the heated hydrocarbon comprises the stream cracker effluent, a cooled steam cracker effluent, a refinery hydrocarbon-containing stream, or a combination thereof. 
     
     
         21 . The process of  claim 17 , further comprising removing a portion of the liquid phase effluent from the process. 
     
     
         22 . The process of  claim 17 , wherein the heavy feed further comprises a carrier liquid mixed with the plastic material. 
     
     
         23 . The process of  claim 17 , further comprising mixing a carrier liquid with at least a portion of the liquid phase effluent to produce a combined liquid phase mixture, wherein the combined liquid phase mixture is heated to produce the heated fluid stream. 
     
     
         24 . The process of  claim 17 , wherein the liquid phase effluent comprises a char, and the process further comprises:
 introducing at least a portion of the liquid phase effluent into a separation vessel; and   separating at least a portion of the char from the at least a portion of the liquid phase effluent to produce a char-lean liquid phase effluent, wherein at least a portion of the char-lean liquid phase effluent is heated to produce the heated fluid stream.   
     
     
         25 . The process of  claim 24 , wherein the heavy feed further comprises a carrier liquid mixed with the plastic material. 
     
     
         26 . The process of  claim 24 , further comprising mixing a carrier liquid with at least a portion of the char-lean liquid phase effluent to produce a combined liquid phase mixture, wherein the combined liquid phase mixture is heated to produce the heated fluid stream. 
     
     
         27 . The process of  claim 22 , wherein the carrier liquid comprises a heat-soaked and/or hydrotreated hydrocarbon stream having an initial boiling point of at least 300° C. 
     
     
         28 . The process of  claim 17 , wherein the plastic material comprises a contaminant-containing polymer and/or the heavy feed further comprises a compound comprising contaminant, and wherein the vapor phase effluent further comprises one or more contaminant-containing compounds, the process further comprising:
 contacting the vapor phase effluent with a guard bed to remove at least a portion of the one or more contaminant-containing compounds to produce a contaminant-lean vapor phase stream, wherein the contaminant-lean vapor phase stream is combined with the heated mixture to produce the combined mixture.   
     
     
         29 . The process of  claim 28 , wherein the plastic material comprises the contaminant-containing polymer, and wherein the contaminant-containing polymer comprises polyvinyl chloride, polyvinylidene chloride, chlorinated polyvinyl chloride, or a mixture thereof. 
     
     
         30 . The process of  claim 17 , wherein the plastic pyrolysis conditions in the vessel comprises a temperature in a range from 300° C. to 550° C. 
     
     
         31 . The process of  claim 17 , wherein the plastic material comprises a nitrogen-containing polymer, a chlorine-containing polymer, an oxygen-containing polymer, a polyethylene polymer, a polypropylene polymer, a polystyrene polymer, a polyamide polymer, polyethylene terephthalate, ethylene vinyl acetate, a butadiene polymer, an isoprene polymer, an isobutylene polymer, or a mixture thereof. 
     
     
         32 . The process of  claim 17 , wherein the hydrocarbon feed comprises crude oil or a fraction thereof. 
     
     
         33 . A process for converting hydrocarbons by pyrolysis, comprising:
 heating a hydrocarbon feed within a convection section of a steam cracking furnace and combining the hydrocarbon feed with an aqueous fluid to produce a heated mixture comprising hydrocarbons and steam, wherein the heating is carried out before, during, and/or after the hydrocarbon feed is combined with the aqueous fluid, and wherein the heated mixture is a two-phase gas/liquid mixture;   introducing the heated mixture and a heavy feed comprising a plastic material into a vessel;   cracking a portion of the plastic material within the vessel under plastic pyrolysis conditions;   obtaining a first liquid phase effluent, a second liquid phase effluent, and a vapor phase effluent exiting the vessel;   heating at least a portion of the first liquid phase effluent to produce a heated first fluid stream;   recycling at least a portion of the heated first fluid stream to the vessel;   heating the second liquid phase effluent within the convection section of the steam cracking furnace to produce a heated second fluid stream;   introducing the heated second fluid stream into a separation drum;   obtaining a vapor phase overhead and a liquid phase bottoms from the separation drum; and   steam cracking the vapor phase overhead within a radiant section of the steam cracking furnace to produce a steam cracker effluent comprising olefins.   
     
     
         34 . The process of  claim 33 , further comprising:
 recycling at least a portion of the vapor phase effluent as a portion of the hydrocarbon feed;   introducing at least a portion of the vapor phase effluent into a gas recovery unit;   introducing at least a portion of the vapor phase effluent into a primary fractionator that receives the steam cracker effluent;   introducing at least a portion of the vapor phase effluent into a process gas compressor system; or   a combination thereof.   
     
     
         35 . The process of  claim 33 , wherein a composition of the first liquid phase effluent is different than a composition of the second liquid phase effluent. 
     
     
         36 . The process of  claim 35 , wherein the first liquid phase effluent comprises a greater concentration of a char as compared to the second liquid phase effluent. 
     
     
         37 . The process of  claim 33 , further comprising:
 periodically stopping introduction of the heated mixture and the heavy feed into the vessel;   periodically stopping recovery of the second liquid phase effluent from the vessel; and   heating the heated mixture within the convection section of the steam cracking furnace to produce the heated second fluid stream such that the heated mixture alone is heated within the convection section of the steam cracking furnace, introduced into the separation drum, and a vapor phase derived from the heated mixture alone is steam cracked within the radiant section of the steam cracking furnace to produce the steam cracker effluent.   
     
     
         38 . The process of  claim 37 , wherein, during the periodic stopping of the introduction of the heated mixture and the heavy feed into the vessel and the periodic stopping of the recovery of the second liquid phase effluent from the vessel, the plastic material in the heavy feed continues to undergo pyrolysis within the vessel. 
     
     
         39 . The process of  claim 33 , further comprising carrying out one or more maintenance operations on the vessel when introduction of the heated mixture and the heavy feed into the vessel is stopped. 
     
     
         40 . The process of  claim 39 , wherein the maintenance operation comprises removing at least a portion of any accumulated char disposed within the vessel. 
     
     
         41 . The process of  claim 33 , wherein at least a portion of the liquid phase bottoms recovered from the separation drum is recycled to the vessel, recycled to make up at least a portion of the hydrocarbon feed heated within the convection section of the steam cracking furnace, or a combination thereof. 
     
     
         42 . The process of  claim 33 , wherein:
 the heavy feed is introduced into the vessel followed by the heated mixture,   the heated mixture is introduced into the vessel followed by the heavy feed,   the heavy feed and the heated mixture are introduced into the vessel as a mixture, or   the heavy feed and the heated mixture are separately co-fed simultaneously into the vessel.   
     
     
         43 . The process of  claim 33 , wherein the first liquid phase effluent is heated in an internal heat exchanger disposed within the convection section of the steam cracking furnace. 
     
     
         44 . The process of  claim 33 , wherein the first liquid phase effluent is heated within an external heat exchanger outside of the steam cracking furnace. 
     
     
         45 . The process of  claim 44 , wherein the first liquid phase effluent is heated within the external heat exchanger by transferring heat from a heated hydrocarbon, a heated aqueous fluid, or a combination thereof, or transfer heat from one or more electrical heating elements, or a combination thereof, and wherein, if present, the heated hydrocarbon comprises the stream cracker effluent, a cooled steam cracker effluent, a refinery hydrocarbon-containing stream, or a combination thereof. 
     
     
         46 . The process of  claim 33 , further comprising removing a portion of the first liquid phase effluent from the process. 
     
     
         47 . The process of  claim 33 , wherein the first liquid phase effluent comprises a char, and the process further comprises:
 introducing at least a portion of the first liquid phase effluent into a separation vessel; and   separating at least a portion of the char from the at least a portion of the first liquid phase effluent to produce a char-lean liquid phase effluent, wherein at least a portion of the char-lean liquid phase effluent is heated to produce the heated fluid stream.   
     
     
         48 . The process of  claim 33 , wherein the plastic material comprises a contaminant-containing polymer and/or the heavy feed further comprises a compound comprising a contaminant, and wherein the vapor phase effluent further comprises one or more contaminant-containing compounds, the process further comprising:
 contacting the vapor phase effluent with a guard bed to remove at least a portion of the one or more contaminant-containing compounds to produce a contaminant-lean vapor phase stream.   
     
     
         49 . The process of  claim 48 , further comprising:
 recycling at least a portion of the contaminant-lean vapor phase effluent as a portion of the hydrocarbon feed;   introducing at least a portion of the contaminant-lean vapor phase effluent into a gas recovery unit;   introducing at least a portion of the contaminant-lean vapor phase effluent into a primary fractionator that receives the steam cracker effluent;   introducing at least a portion of the contaminant-lean vapor phase effluent into a process gas compressor system; or   a combination thereof.   
     
     
         50 . The process of  claim 48 , wherein the plastic material comprises the contaminant-containing polymer, and wherein the contaminant-containing polymer comprises polyvinyl chloride, polyvinylidene chloride, chlorinated polyvinyl chloride, or a mixture thereof. 
     
     
         51 . The process of  claim 33 , wherein the plastic pyrolysis conditions in the vessel comprises a temperature in a range from 300° C. to 500° C. 
     
     
         52 . The process of  claim 33 , wherein the plastic material comprises a nitrogen-containing polymer, a chlorine-containing polymer, an oxygen-containing polymer, a polyethylene polymer, a polypropylene polymer, a polystyrene polymer, a polyamide polymer, polyethylene terephthalate, ethylene vinyl acetate, a butadiene polymer, an isoprene polymer, an isobutylene polymer, or a mixture thereof. 
     
     
         53 . The process of  claim 33 , wherein the hydrocarbon feed comprises crude oil or a fraction thereof. 
     
     
         54 . The process of  claim 33 , wherein the vessel comprises a first vessel and a second vessel, and wherein the heated mixture and the heavy feed are batch processed in the first vessel and the second vessel.